JP2013508985A - Directly mounted photovoltaic device with improved adhesion and method thereof. - Google Patents

Abstract

The present invention is based on a photovoltaic device suitable for being mounted directly on a structure. The device comprises a photovoltaic cell assembly having a top portion that allows for the transmission of light energy to the photoactive portion of the photovoltaic device and a bottom surface having a bottom bonding zone for conversion to electrical energy. An active part comprising a body, and a region for receiving a fastener for coupling the device to the structure, and having an upper bonding zone on the upper surface, directly adjacent to and coupled to the active part Comprising an inert portion,
One of the top bonding zone and the bottom bonding zone includes a first bonding element and the other includes a second bonding element, wherein the second bonding element is adjacent to the vertically overlapping light. It is designed to bond the device to its adjacent device or to the structure by interacting with a first bonding element on the electromotive force device.

Description

This invention was made with US government support under the agreement DE-FC36-07G017054 awarded by the Department of Energy. The US government has certain rights in this invention.
Claims of priority This application is based on US Provisional Application Nos. 61 / 253,980 (filed on Oct. 22, 2009) and 61 / 257,488 (filed on Nov. 3, 2009). Claim priority of the filing date of the letter. The contents of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD OF THE INVENTION The present invention relates to photovoltaic devices and methods that are directly attached to a structure, and more particularly, adapted to be directly attached to a building structure, such as a roof deck or wall. The present invention relates to a photovoltaic single and a method thereof.

  Attempts to improve advanced technologies in the field of solar power generation, specifically in the field of building-mounted power generation, have been of increasing industry interest over the last few years. Part of building-mounted power generation is building-integrated photovoltaic technology (BIPV), in which the photovoltaic element is an integral part of the building {eg, shingles or exterior resistance such as siding. Provide a weather covering}. Of particular importance is the goal of providing a reliable and durable solar power system that yields the highest kilowatt hours (KwH) at the lowest cost. Some of the issues associated with reaching this goal are easy to assemble and install, have a relatively high KwH output, and are durable (eg, possible environmental conditions such as relatively strong wind and rain) It relates to the power generation system's ability to hold down for a certain period of time. One specific issue related to durability is the wind load measured, for example, through the lift resistance test of the roof assembly according to (Underwriters Laboratories) UL 1897. This is the ability of the system not to be damaged, for example, when it is exposed to winds of more than 100 miles per hour or stronger. One specific issue related to ease of installation is that it is necessary to prevent BIPV from becoming active (eg, generating electricity) before it is desired. Other issues relate to the inherently low coefficient of friction (eg, slippery) of BIPV, and the ease of walking on the installer's system surface, and potential packaging and shipping issues.

  The current state of building-mounted solar power systems takes many forms, but in general, complex mounting structures (eg, inner box frames, platform risers, such as San Jose, California, USA) A solar panel that is attached to a SunPower Model 31 (registered trademark) according to, and forms a solar power assembly with a predetermined cross-sectional thickness (eg 25 mm or more) and high rigidity (eg 70000 MPa “megapascal” elastic modulus), Or a flexible laminate structure (eg, Rochester Hills, Michigan, with a cross-sectional thickness (eg, about 1.5-7 mm) and stiffness (about 5-50 MPa) similar to typical asphalt roofing shingles. Roll-type solar laminates provided by Uni-Solar® from USA). Notably, traditional cedar shake type roofing singles are typically about 1-5 times thicker than typical asphalt roofing singles and have a stiffness of about 4000-9000 MPa, but wind It is unlikely that you will suffer from the problem of lifting. It is not surprising that a SunPower type system does not suffer from wind lift problems (due to complex mounting structures and / or high stiffness). It is not surprising that Uni-Solar type systems can overcome the problem of wind lift because the entire laminate is glued to the building structure.

  The above problem of wind load can be influenced by changing the slope of the device (eg at the installation position) and changing the height / flatness of the mounting surface.

  Documents relating to this technology include the following patent documents: US Patent Application Publication Nos. 2009/0000220; 2008/0245404; 2008/0245399; 2008/0196358; 2008/0196231; No. 2008/0083169; No. 2008/0000173; No. 2007/0295391; No. 2007/0193135; No. 2007/0229924; No. 2004/0216405; No. 2004/0206035; Nos. 2004/0083673; 2003/0188500; 2003/0154680; 2002/0066235; US Pat. Nos. 7,299,598; 7,204063; 7,178,295; No. 4; No. 6845592; No. 6758019; No. 6725623; No. 6398556; No. 6247289; No. 6148570; No. 5950387; No. 5239802; No. 4686808; Nos. 4641472; Nos. 4641471; Nos. 4627207; Nos. 4586301; Nos. 2631887; RE38988; and International Publication Nos. 2007/123927; 2007/079382; 2003/071047 No. brochure (all of which are incorporated herein by reference for all purposes).

  The present invention relates to a photovoltaic device mounted directly on a structure (building structure, wall and / or roof deck) and a method thereof. The present invention addresses one or more of the above issues / problems.

  Furthermore, the present invention relates to a new type of building-mounted solar power generation system. The new system is a plurality of individual “single-like” structures that are attached to the building structure with fasteners (eg, nails or screws), with high stiffness (eg, up to about 10,000 MPa) and about It has a thickness of 15 mm. Surprisingly, given the high stiffness / thickness of the system (eg, similar to cedar shake), this system requires the improvements disclosed herein to achieve the above goals. Sometimes.

  Thus, according to one aspect of the present invention, a photovoltaic device suitable for direct mounting on a structure, wherein the light energy is applied to the photoactive portion of the photovoltaic device for conversion to electrical energy. An active portion including a photovoltaic cell assembly having a top surface portion that allows transmission of light and a bottom surface having a bottom bonding zone, and a fastener for coupling the device to the structure And an inactive portion directly adjacent to and coupled to the active portion having a top bonding zone on the top surface, wherein one of the top bonding zone and the bottom bonding zone is Including a first bonding element and the other including a second bonding element, wherein the second bonding element is adjacent to a vertically overlapping photovoltaic. By interacting with the first bonding element on the force device, the device is designed to bond to that of the adjacent device or the structure, is considered a photovoltaic device.

  The present invention further includes features described herein, eg, the first bonding element includes an adhesive that forms the adhesive bonding element, and the second bonding element is adapted to receive at least a portion of the first bonding element. The first bonding element has a coextensive extent at the bottom surface of the active part with the periphery of the active part or is located within 25 mm from the periphery of the active part; the second bonding element comprises: Including at least one recessed pocket for receiving at least a portion of the first bonding element; at least one recessed pocket having a pocket depth of at least 1.0 mm; A removable release liner disposed on the outer surface of the adhesive, the release liner being Being removed to allow the first and second bonding elements, or the first bonding element and structure, to form a bond; a removable release liner is provided laterally from the periphery of the photovoltaic device Extending at least 10 mm to form a side extension and being folded back at least in one of the bonding zones; a removable release liner covers a portion of the upper portion of the active portion Cover and be opaque (e.g., opaque) or light restricted to prevent the cell from generating electricity until it is removed; a removable release liner is accessible to the installer Include printed installation instructions; Removable release liner includes exterior with anti-slip The bonding element maintains a minimum peel force of 3 PLI (pounds per linear inch) according to ASTM D 903-98, more preferably 5 PLI, and most preferably 10 PLI at temperatures between -40 ° C. and 85 ° C. And a pressure sensitive adhesive having an elongation of> 500%, more preferably> 1000% according to ASTM D 412-06; a portion of the top bonding zone, the bottom bonding zone, or both is a flat surface Including a patterned surface that increases the surface area by more than 5% relative to the surface; the first and second bonding elements include surface fasteners having a predetermined assembly thickness, and the surface fastener assembly thickness is at least one recess. At least 90% in the interior pocket; first bonding element, second bonding element, Both are continuous elements or are configured as discontinuous elements separated by a predetermined space; the device is at or near the edge opposite the active part It can be characterized by one or any combination of having an increased thickness.

  Thus, according to another aspect of the invention, a method for assembling at least two photovoltaic devices on a structure comprising the steps of: a. Removable release liner; an activity comprising a photovoltaic cell assembly having a top surface portion that allows light energy to be transferred to the photoactive portion for conversion to electrical energy and a bottom surface having a bottom bonding zone A portion; and an inactive portion directly adjacent to and coupled to the active portion, having a region for receiving a fastener for coupling the device to the structure, and having an upper bonding zone on the top surface Providing two photovoltaic devices; b. Providing a plurality of mechanical fasteners; c. Placing one of the at least two photovoltaic devices on the structure; d. Securing the disposed photovoltaic device to the structure by at least two of a plurality of mechanical fasteners; e. Placing a second of the at least two photovoltaic devices, partly on the structure and partly above the photovoltaic device of step c; f. Securing the disposed second photovoltaic device to the structure by at least two of the plurality of mechanical fasteners; and g. Depressing a portion of the upper surface portion of the disposed second photovoltaic device to complete the assembly of the at least two photovoltaic devices on the structure, the at least two photovoltaic devices on the structure A method of assembling can be considered.

  The invention further provides features described herein, for example, wherein at least two photovoltaic devices include a removable release liner, the release liner covering at least one of the bonding zones, Extending from the periphery to the side by at least 10 mm to form a side extension and being folded back at least in one of the bonding zones; pulling the side extension before the depression step Removing the removable release liner; the removable release liner covers a portion of the top portion of the active portion and is opaque to prevent the cell from generating electricity until it is removed Or be light limiting; make a removable release liner easier to use for installers Including lint has been installed instructed; removable release liner can be characterized by one or any combination of including an outer surface having a slip.

  Of course, as shown and described herein, the above-referenced embodiments and examples are non-limiting because the scope of the present invention includes others.

FIG. 1 is a top perspective view showing an assembled photovoltaic device group as an example. FIG. 2 is a top perspective view showing the single photovoltaic device of FIG. FIG. 3 is a bottom perspective view of the single photovoltaic device of FIG. FIG. 4 is a top perspective view showing a portion of a single photovoltaic device having a typical pocket. FIG. 5A is a side view showing a typical pocket profile section. FIG. 5B is a side view showing a typical pocket profile section. FIG. 5C is a side view showing a typical pocket profile section. FIG. 5D is a side view showing a typical pocket profile section. FIG. 5E is a side view showing a typical pocket profile section. FIG. 6 is a top perspective view of a single photovoltaic device having a typical liner strip. FIG. 7 is a side view of the exemplary liner strip of FIG. 6 with a folded portion. FIG. 8 is a top perspective view of a single photovoltaic device having another exemplary liner strip. FIG. 9 is a top perspective view of a single photovoltaic device and a typical end cap in an exploded state. FIG. 10 is a top perspective view showing a single photovoltaic device and a typical end cap assembled.

  The present invention relates to a photovoltaic assembly system for securing and / or aligning a plurality of photovoltaic device assemblies 10 (or overlapping photovoltaic device arrays) that are at least vertically adjacent (overlapping) to each other. . Device 10 is preferably mounted directly to a structure (eg, a building structure, wall and / or roof deck). The present invention seeks to overcome the problem of wind lift using unique connection means and, if necessary, using solutions that address some of the other problems that may arise. FIG. 1 shows three photovoltaic devices 10 in an assembled arrangement (e.g. from a lower photovoltaic device array consisting of two horizontally adjacent devices 10 and one device 10). An overlapping upper photovoltaic device array).

Photovoltaic device In general, the photovoltaic device 10 contemplated by the present invention claims the priority of PCT application PCT / US09 / 42496 (US provisional application 61 / 050,341; both of which are for all purposes) Are structurally similar to those disclosed in (incorporated by reference). This device is generally described as an assembly of multilayer laminates (including polymeric and non-polymeric layers) sealed on at least three sides by a polymeric casing. The apparatus 10 preferably has a structure, such as a building roof deck (with or without other items such as roofing felt or previous layers of asphalt singles), intermediate retaining structures (e.g. frames, rails, or It is adapted for direct mounting without the need for risers). Broadly speaking, the device 10 is adapted to be installed on a building (eg, a roof) in the same manner as a standard asphalt single. In a preferred embodiment, the device 10 is rectangular and has a generally flat profile, and the thickness is less than about 20 mm, more preferably less than about 15 mm, and generally greater than about 2 mm, more preferred. Is greater than about 5 mm. Other shapes (square, circular, polygonal, etc.), other profiles (eg, curved, stepped, etc.), and other thicknesses (greater than about 15 mm) are also contemplated.

  The photovoltaic device 10 is further defined as a device 10 comprising an active portion 20 and an inactive portion 40 directly adjacent to and coupled to the active portion 20, as shown in FIGS. May be.

  The active portion 20 may include a photovoltaic cell assembly 22 having a top surface portion 24 that allows light energy to be transmitted to the photoactive portion 26 of the photovoltaic device 10 for conversion to electrical energy. . The active portion 20 also has a bottom portion 28 having a bottom bonding zone 30. The active portion 20 has a peripheral edge 32 and a thickness 34.

  Inert portion 40 is a region for receiving fasteners (eg, screws, nails, or other mechanical fasteners, not shown) adapted to couple device 10 to a structure (eg, roof deck or wall). 42 may be included. Inactive portions may be defined as a top portion 44, a bottom portion 46, and an upper bonding zone 48. The inactive portion 40 has a peripheral edge 50 and a thickness 52. The inert portion 40 may include coupling means, such as an electrical connector housing (not shown), that function to connect the plurality of devices 10 together.

  The top bonding zone 48 and the bottom bonding zone 30 may be further defined to include a first bonding element 36 and the other includes a second bonding element 50. Functionally, the bonding elements 36, 50 may be designed to interact with each other when the device 10 is vertically overlapped with an adjacent photovoltaic device 10. If there is no device directly under the device, one of these bonding elements can also bond the device 10 to the structure.

  If desired, the bonding zones 30, 48 may include a patterned surface. The patterned surface increases the surface area by more than 5%, preferably by more than 15% and most preferably by more than 25% relative to a flat surface. It is also conceivable to incorporate structures with vertical components (eg, protrusions extending from surfaces 28 and / or 44), for example, to introduce shear components necessary for adhesive failure. It is also conceivable to add a coarse mesh structure to prevent twisted patch-type defects.

  In one preferred embodiment, the upper portion 44 of the inert portion is accompanied by and accompanied by a filler comprising polyethylene, polypropylene, thermoplastic polyolefin, olefin block copolymer, thermoplastic urethane, silicone, and specifically glass filler. Many other polymers may be included.

  In one preferred embodiment, the bottom portion 28 of the active portion 20 includes thermoplastic polyolefin (TPO), thermoplastic elastomer, olefin block copolymer (OBC), natural rubber, synthetic rubber, polyvinyl chloride, and other elastomers and plastomers. Materials, polyolefins, polyesteramides, polysulfones, acetals, acrylics, polyvinyl chlorides, nylons, polycarbonates, phenols, polyetheretherketones, polyethylene terephthalates, epoxies, and these composites or any combination filled with glass and minerals May be included.

Recessed Pocket As shown in FIG. 4, the device 10 may include at least one recessed pocket 60. The pocket 60 may be located on the top surface 28 or bottom surface 46 or on the top surface 24, 44 and generally has a depth less than the thickness 34, 52. In one preferred embodiment, the pocket depth 62 of the pocket 60 is at least about 1.0 mm. The pockets may straddle the device as adjacent pockets (eg, with side-to-side contact) or form segments of non-adjacent pockets (eg, multiple pockets 60). The pocket may be of any shape (eg, square, rectangular, trapezoidal, circular, etc.), and as shown in FIGS. 5A-E, any pocket profile 64 (eg, concave, square, triangular, circular, Or any combination thereof). Preferably, the pocket 60 has a geometry and profile adapted to receive either or both of the bonding elements 36,50.

Bonding elements Bonding elements 36, 50 are generally used to bond (bond) two devices 10 that are at least partially vertically adjacent to each other, or in the case of a “bottom” device 10, to connect the device 10 to a structure. It functions as a means for (bonding). Bonding elements 36, 50 may be adhesive, hook-and-loop fastener assemblies (hook and loop fastener assemblies), or adjacent surfaces (eg, if adhesive is present only on one side of the joint prior to assembly, The second element 50 may be an adjacent surface). Positionally, at least one of the bonding elements is preferably located at or near the periphery of one of the devices 10, although the bonding element may be located closer to the middle of the device 10. Good. In one preferred embodiment, the first bonding element 36 is coextensive with the periphery of the active portion at the bottom portion 28 of the active portion 20 or is located within about 25 mm from the periphery of the active portion. For convenience, the term “arranged” means the position of an element, and “combined arrangement” means the position and that the elements are connected to each other.

  In the case of an adhesive bonding element, the selected adhesive is at least partially compatible with the surface to be bonded (eg, the polymeric surface of the device 10 or structure). Generally, the bonding element has a minimum peel force of about 3 PLI (pounds per linear inch) according to ASTM D 903-98 at temperatures between −40 ° C. and 85 ° C., more preferably about 5 PLI, and most preferably about 10 PLI. It is preferred to include an adhesive that maintains the above and has an elongation according to ASTM D 412-06 of> 500%, more preferably> 1000%. This is preferred if the adhesive maintains a thickness (after assembly) of about 0.5 mm or more, more preferably about 0.7 mm to about 2.0 mm.

  In one preferred embodiment, the adhesive bonding element comprises a pressure sensitive adhesive (pressure sensitive adhesive PSA) or a contact adhesive. The contact adhesive bonds to the surface upon contact (no cure time is required) and bonds to each surface (eg, adjacent device 10, or structure, or asphalt single) with very little pressure. These may be utilized in solvent and latex, or aqueous form. Adhesives and contact adhesives are often considered to be based on non-crosslinked rubber adhesives, acrylics, or polyurethanes. Adhesives are also considered to be aggressive and permanently tacky, adhere without requiring pressure above finger or hand pressure, and form a viscoelastic bond that does not require activation by water, solvent or heat. It is done.

  Adhesives and contact adhesives can be utilized in a wide variety of chemical compositions or chemical systems. Some possible PSAs include acrylic and methacrylate adhesives, rubber based adhesives, styrene copolymers (SIS / SBS) and silicones. Acrylic adhesives are known to have superior environmental resistance and fast cure time compared to other resin systems. Acrylic adhesives often use acrylate systems. To form a hot melt PSA adhesive, ethylene ethyl acrylate (EEA) or ethylene methyl acrylate (EMA) copolymer is used. Natural rubber, synthetic rubber, or elastomer sealants and adhesives can be based on various silicones, polyurethanes, chloroprene, butyl, polybutadiene, isoprene, or neoprene. In a preferred embodiment, the PSA comprises an ethylene propylene copolymer tape, a rubber-based adhesive, a synthetic rubber-based tape, a PE foam tape, and an acrylic structure, and / or a multilayer structure of the above combination, such as acrylic / PET / acrylic. The most preferred adhesive is butyl adhesive tape. Some important features of the adhesive are adhesives that have instantaneous aggressive adhesion / adhesion to the roof structure without the use of secondary materials such as primers, and in extreme weather conditions ( For example, it is conceivable to include an adhesive that maintains a high strength at or after long periods of high temperatures (eg, 85 ° C.) and that provides a watertight connection of the component to the roof structure. Some examples that are commercially available (and have registered trademarks) are: butyl: Ashland Plioseal Seam tape, Adco PVA series (eg PVA 600BT and 650BT); rubber system: Adco SP-505 curable roof seam tape; Synthetic rubber system: MACtac TM1039 and GS series; ethylene propylene copolymer; SikaLastomaer 68; acrylic / PET / acrylic; and Tesa Tape 4965 PET reinforced; and PE foam tape: may include Tesa Tape 62932 D / C foam tape it can.

  For hook-and-loop fastener assemblies, the minimum peel force (between hook and loop) is about 3 PLI (pounds per linear inch) according to ASTM D 903-98 at temperatures between -40 ° C and 85 ° C. More preferably about 5 PLI, and most preferably about 10 PLI or more. In this case, the hook-and-loop fastener assembly is bonded to device 10 (eg, via adhesive, heat staking, overmolding, ultrasonic welding, or mechanical fastening).

Removable Release Liner When using the adhesive described above, it may be necessary to include a removable release liner 80 as shown in FIGS. The removable release liner 80 can be used to assist in shipping and installation, and to facilitate alignment and positioning of the two devices 10 that are adapted to be bonded together. The liner 80 may also provide additional functionality, discussed as any of the following aspects.

  It is contemplated that the liner 80 may consist of a relatively thin (eg, less than about 1.0 mm thick) essentially polymeric film. The liner 80 may be a single layer film or may be a multilayer film having multiple layers of the same or different materials. Some of the possible materials are high density polyethylene (HDPE) and polycoated kraft release paper (liner). Properties such as thickness and flexibility are considered to be important to some extent.

  In one preferred embodiment, the removable release liner may be disposed on the outer surface of the adhesive and the first bonding element and the second bonding element or the first bonding element and the structure form a bond. Removed to make it possible to do.

  In another preferred embodiment, the removable release liner 80 extends laterally from the periphery of the photovoltaic device by at least 10 mm to form a lateral extension 82. The liner 80 is also folded at least in one of the bonding zones. The folding makes it easier to peel off the liner 80.

  In another preferred embodiment, the removable release liner covers a portion of the photoactive portion 26 and the cell is electrically (eg, for any electricity or system or installer safety) until it is removed. Opaque (e.g., opaque) or light limiting (e.g., at least for the desired wavelength or sufficient to prevent power generation) to prevent the generation of high quantities of electricity) Is restrictive).

  If desired, the removable release liner may include printed installation instructions (e.g., text and / or pictographic information) for ease of use by the installer. If desired, the removable release liner may include an outer surface 84 with a non-slip (eg, texture or high coefficient of friction).

The amount of pressure applied at or near the leading edge of the device 10 to overcome local device geometry, for example, changes in the slope of the device (eg at the installation location), as well as changes in height / flatness of the mounting surface It may be desirable to increase. One way to achieve this is to shift the pressurization point and force transmission in the device 10.

  One possible way to shift the pressure point and force transmission is to increase the thickness of the device 10 at or near the edge 92. This can be achieved by locally changing the geometry of the device 10 (eg, a local thickness change of about 5-15 mm).

  This increase in thickness can be achieved by increasing the thickness of the device by changing the shape of the mold or by increasing the height of the device 10 locally (e.g., before or during installation). It is realizable by adding to. It is contemplated that any component, such as a trim strip or clip that can be fastened to the device 10, can serve this purpose.

  One illustrative example in which a single separate component (eg, end cap 90) has been added is shown in FIGS. In this example, the separate component is a U-shaped passage over one edge of the device. The end cap 90 is placed on the upper edge 92 of the device 10. It may be desirable to set the height below the fastening area 42 of the device 10 by fastening the device 10 as close as possible to this position (eg, within about 25 mm) (eg, nailing). It is done.

Method Also contemplated by the present invention is a method of assembling at least two photovoltaic devices on a structure (device 10 above). The method of the present invention comprises a. Removable release liner; an activity comprising a photovoltaic cell assembly having a top surface portion that allows light energy to be transferred to the photoactive portion for conversion to electrical energy and a bottom surface having a bottom bonding zone A portion; and an inactive portion directly adjacent to and coupled to the active portion, having a region for receiving a fastener for coupling the device to the structure, and having an upper bonding zone on the top surface Providing two photovoltaic devices; b. Providing a plurality of mechanical fasteners; c. Placing one of the at least two photovoltaic devices on the structure; d. Securing the disposed photovoltaic device to the structure by at least two of a plurality of mechanical fasteners; e. Placing a second of the at least two photovoltaic devices, partly on the structure and partly above the photovoltaic device of step c; f. Securing the disposed second photovoltaic device to the structure by at least two of the plurality of mechanical fasteners; and g. Depressing a portion of the upper surface portion of the second photovoltaic device disposed to complete the assembly of at least two photovoltaic devices on the structure.

  Optionally, the method includes at least two photovoltaic devices including a removable release liner; the release liner covers at least one of the bonding zones and is lateral to the photovoltaic device. Extending at least 10 mm to form a side extension and being folded back at least in one of the bonding zones; removable by pulling the side extension before the depression process Removing the release liner; a removable release liner covers a portion of the top portion of the active portion and is opaque or light limited to prevent the cell from generating electricity until it is removed Printed installation instructions so that a removable release liner is accessible to the installer Including it; removable release liner, that includes an outer surface having a slip may contain.

  Unless otherwise noted, the dimensions and geometric shapes of the various structures shown herein are not intended to limit the invention, and other dimensions or geometric shapes are possible. Multiple structural components can be provided by a single integrated structure. Alternatively, a single integrated structure may be divided into a plurality of separate components. In addition, while features of the invention have been described in connection with only one of the illustrated embodiments, such features may be used in accordance with a given application, one or more of the other embodiments. May be combined with other features. Needless to say, the fabrication and operation of the unique structure herein also constitutes a method according to the present invention.

  A preferred embodiment of the present invention has been disclosed. Those skilled in the art will recognize that certain variations are within the teachings of the present invention. Accordingly, the following claims should be studied to determine the true scope and content of the present invention.

  Any numerical value quoted in the above application shall be incremented by one unit if any low and high values are separated by at least 2 units, all values from low to high Have By way of example, if the amount of components or process variables, such as temperature, pressure, and time, etc. are described as being for example 1 to 90, preferably 20 to 80, more preferably 30 to 70, 15 to 85. Values such as 22-68, 43-51, 30-32, etc. shall be explicitly listed herein. For values that are less than 1, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 as appropriate. These are just examples of what is specifically intended, and all possible combinations of numerical values between the lowest and highest values listed are considered to be clearly stated in this application as well. it can.

  Unless otherwise noted, all ranges include both endpoints and all values between the endpoints. Where “about” is used in connection with a range, this applies to both ends of the range. Thus, “about 20-30” ranges from “about 20 to about 30”, including at least the designated endpoint.

  The disclosures of all articles and references, including patent application specifications and publications, are incorporated by reference for all purposes.

  The term “consisting essentially of” to describe a combination refers to the identified element, component, component, or process, as well as the basic and novel characteristics of the combination. It shall include other elements, components, components or processes that do not have a significant effect.

  Where the term “comprising” and “including” is used herein to describe a combination of an element, component, component, or process, the element, component, component, or process is also used. An embodiment consisting essentially of:

  A single element, component, component, or process can provide a plurality of elements, components, components, or processes. Alternatively, a single element, component, component, or process can be divided into separate elements, components, components, or processes. The disclosure of “a” or “one” to describe an element, component, component, or process is not intended to exclude an additional element, component, component, or process. All references herein to elements or metals belonging to a group relate to the Periodic Table of Elements (issued in 1989 by the Periodic Table of the Elements, CRC Press, Inc., which is copyrighted). Any reference to a group shall refer to the group reflected in this periodic table using the IUPAC group numbering system.

Claims (21)

A photovoltaic device suitable for mounting directly on a structure,
An activity comprising a photovoltaic cell assembly having a top surface portion that allows the transmission of light energy to the photoactive portion of the photovoltaic device for conversion to electrical energy and a bottom surface having a bottom bonding zone An inactive portion directly adjacent to and coupled to the active portion having a portion and a region for receiving a fastener for bonding the device to the structure and having an upper bonding zone on the top surface;
Comprising
One of the top bonding zone and the bottom bonding zone includes a first bonding element and the other includes a second bonding element, wherein the second bonding element is adjacent to the vertically overlapping light. Designed to bond the device to its adjacent device or to the structure by interacting with a first bonding element on the electromotive force device;
Photovoltaic device.   The first bonding element includes an adhesive that forms an adhesive bonding element, and the second bonding element includes a compatible material for receiving at least a portion of the first bonding element. The device described.   The apparatus according to claim 1 or 2, wherein the first bonding element has the same extent as the periphery of the active part on the bottom surface of the active part or is located within 25 mm from the periphery of the active part. .   4. An apparatus according to any one of claims 1 to 3, wherein the second bonding element includes at least one recessed pocket for receiving at least a portion of the first bonding element.   The apparatus of claim 4, wherein the at least one recessed pocket has a pocket depth of at least 1.0 mm.   The first bonding element further comprises a removable release liner disposed on the outer surface of the adhesive, the release liner comprising the first bonding element and the second bonding element, or the first bonding element and 6. A device according to any one of claims 2 to 5, wherein the device is removed to allow the structure to form a bond.   The removable release liner extends laterally from the periphery of the photovoltaic device by at least 10 mm to form a lateral extension and is folded back at least in one of the bonding zones. The apparatus of claim 6.   The removable release liner covers a portion of the top portion of the active portion and is opaque or light limited to prevent the cell from generating electricity until it is removed. Item 8. The device according to Item 6 or 7.   9. An apparatus according to any one of claims 6 to 8, wherein the removable release liner includes printed installation instructions for ease of use by the installer.   The apparatus according to any one of claims 6 to 9, wherein the removable release liner comprises an outer surface with a non-slip.   The bonding element maintains a minimum peel force of 3 PLI (pounds per linear inch) according to ASTM D 903-98, more preferably 5 PLI, and most preferably 10 PLI at a temperature of −40 ° C. to 85 ° C. 11. An apparatus according to any one of the preceding claims, comprising an adhesive having an elongation according to ASTM D 412-06 of> 500%, more preferably> 1000%.   12. Any one of claims 1 to 11, wherein a portion of the top bonding zone, the bottom bonding zone, or both includes a patterned surface that increases the surface area by more than 5% relative to a flat surface. The device according to item.   5. The first and second bonding elements include a hook-and-loop fastener having a predetermined assembly thickness, wherein the hook-and-loop fastener assembly thickness is disposed at least 90% within the at least one recessed pocket. 13. The apparatus according to any one of up to 12.   The first bonding element, the second bonding element, or both are either continuous elements or configured as discontinuous elements separated by a predetermined space. The device according to item.   15. A device according to any one of the preceding claims, wherein the device has an increased thickness of the inactive part at or near the edge opposite the active part. A method of assembling at least two photovoltaic devices on a structure,
a. Removable release liner;
An active portion comprising a photovoltaic cell assembly having a top surface portion allowing to transmit light energy to the photoactive portion for conversion to electrical energy, and a bottom surface having a bottom bonding zone; and the apparatus At least two photovoltaics having an area for receiving fasteners for bonding to the structure and having an upper bonding zone on the top surface and including an inactive portion directly adjacent to and bonded to the active portion. Prepare a power device;
b. Provide multiple mechanical fasteners;
c. Placing one of the at least two photovoltaic devices on the structure;
d. Securing the disposed photovoltaic device to the structure by at least two of the plurality of mechanical fasteners;
e. Placing a second of the at least two photovoltaic devices, partly on the structure and partly above the photovoltaic device of step c;
f. Securing the disposed second photovoltaic device to the structure by at least two of the plurality of mechanical fasteners; and g. Depressing a portion of the top surface portion of the disposed second photovoltaic device to complete the assembly of the at least two photovoltaic devices on the structure, including at least two photovoltaic devices on the structure. A method of assembling a power device.   The at least two photovoltaic devices include a removable release liner that covers at least one of the bonding zones and extends laterally from the periphery of the photovoltaic device by at least 10 mm. 17. The method of claim 16, wherein the method forms a lateral extension and is folded at least in one of the bonding zones.   The method of claim 17 including the step of removing the removable release liner by pulling the lateral extension prior to the step of pressing.   19. The removable release liner covers a portion of the top portion of the active portion and is opaque or light limiting to prevent the cell from generating electricity until it is removed. The method according to any one of the above.   20. A method according to any one of claims 16 to 19, wherein the removable release liner includes printed installation instructions for ease of use by the installer.   20. A method according to any one of claims 16 to 19, wherein the removable release liner comprises an outer surface with a non-slip.

Images